Means for prefabricating brick panels

ABSTRACT

Prefabricated brick panels are formed course by course on a table, starting against a movable footing course. Course spacers and individual brick spacers are laid in advance of each course and brick respectively. The table has a roller platform projecting from the edge opposite that alongside which the courses are laid. The footing and finished courses are successively pushed towards the platform to bear against it. When sufficient courses are laid to constitute a panel a cement grout is poured between the bricks. As soon as it has stiffened enough to support the bricks as a panel the table is rotated into the vertical and the panel rolled off in the plane. The footing riding the rollers of the platform for further curing of the panel.

0 United States Patent [151 3,640,046

Anderson et al. 1 Feb. 8, 1972 54] MEANS FOR PREFABRICATHNG BRHCK3,032,850 5/1962 Russell ..25/1 R x PANELS 3,238,589 3/1966 McClamey..52/749 X [72] Inventors: Yngve R. Anderson, Streetsville, Ontario; P EC F George K. Escott, Willowdale, Ontario, 32: f both of Canada y [73]Assignee: Canadian Structural Clay Association, [57] ABSTRACT wlllowdaleOmano Canada Prefabricated brick panels are formed course by course on a[22] Filed: Jan. 22, 1970 table, starting against a movable footingcourse. Course spacers and individual brick spacers are laid in advanceof [21 1 Appl' 4844 each course and brick respectively. The table has aroller platform projecting from the edge opposite that alongside whichU-S. B the courses are 'I'he and finished courses are suc. [51] Int. Cl..E04g 21/22 cessively pushed towards the p|atform to bear again it w[58] Field of Search "52/749, 122; 25/ l 1 l B; sufficient courses arelaid to constitute a panel a cement grout 249/ 137 is poured between thebricks. As soon as it has stiffened enough to support the bricks as apanel the table is rotated [56] Reterences cued into the vertical andthe panel rolled off in the plane. The foot- UNITED STATES PATENTS ingriding the rollers of the platform for further curing of the panel.1,623,625 4/1927 Lake ..25/l B 2,807,070 9/l 957 Thomas ..25/1 B 9Claims, 6 Drawing Figures PATENTEIJ FEB 81372 SHEET 1 OF 2 FIG. I n2lnven tors YNGVE RANDERSON GEORGE K. ESCOTT mmmm awn SHEET 2' OF 2 FIG.5

Inventors YNGVE R.ANDERSON GEORGE K. ESCOTT by: M

MEANS FOR PREFABRECATING BRICK PAliEllfi This invention relates to anovel method process and apparatus for prefabricating brick panels fortransfer from the manufacturing premises to the site on which they areto be erected. In referring to bricks throughout this specification, itas at the outset explained that by such term it is intended to includebricks of all materials, of whatever shape, also hollow tiles, panels ofrough faced stone work and all structural monolithic forms to which themethod or process described may apply or which may be prefabricated intopanel form by the use of the apparatus herein described.

It is common to prefabricate brick panels. One technique consists ofprefabricating bricks upon, and bonding the same to, a rear concretepanel. Another consists of prefabricating brick panels upon an easelpositioned at an incline or in the subvertical. Still another techniqueutilizes a table which may be rotated into the vertical after theprefabrication of a panel thereon. To facilitate movement of the panelswhile fragile because the cement has not been fully cured, dowling ofthe bricks in various ways has been resorted to, together with otherways of maintaining the integrity of the panel as with a crane or thelike to a stacking station such as cramping the panel between oppositeedge clamps or clamping bars. All such techniques as are known howeverare deemed to be too slow or costly, or insusceptible to adequatequality control and hence be liable to unacceptability in meetingbuilding code specifications. All such methods as are known have failedto commend themselves to the brick industry of North America.

The disadvantages of the known prior art may be overcome by theutilization of a powered table, movable between the horizontal and thefully vertical after a set or sufficient number of bricks to form apanel have been laid along one edge of the table following the placementof a footing beam parallel and adjacent to such edge and after a cementgrout has been poured on the set of bricks and the same has stiffenedenough to permit the table to be rotated into the vertical at which timethe weight of the now selfsupporting panel on its footing may betransferred to an elongated roller platform from which it may be rolledoff in its plane and parallel to the table surface plane usually ontoanother set of rollers which set may either be stationary and alignedwith additional sets or itself transferrable whereby, if desired, thepanels may be stored like library shelving with passages therebetweenfor inspection of each side and for the free access of curing air,steam, forced draft or the like, all to produce an invention which isbelieved represents a marked advance in the art from various technicalpoints of view and should effect economies in the manufacturing ofprefabricated brick panels thus making such prefabrication economicallyfeasible and competitively equal or advantageous to or over otherbuilding means extant in advanced industrial countries.

With the foregoing in view, and such other or further purposesadvantages or novel features as may become apparent from considerationof this disclosure and specification, the present invention consists ofthe inventive concept which is comprised, embodied, embraced, orincluded in the product, method, process, construction, composition,arrangement or combination of parts, or new use of any of the foregoing,herein exemplified in one or more specific embodiments of such concept,reference being had to the accompanying Figures in which:

FIG. 1 is a perspective representation of the invented table in itsvertical position as viewed from the rear, showing a fragment of anadjacent roller platform.

FIG. 2 is a perspective representation of a lower corner of the inventedtable showing the front thereof, the supporting means or movable footingand roller platform, also the fragmentary portion of an adjacent rollerplatform being the same as that shown in the accompanying FIG. 1.

FIG. 3 is a perspective representation of the invented table with acompleted brick panel lying thereon, in the horizontal, together with afragmentary portion of an adjacent roller platform as shown in FIGS. 1and 2.

FIG. 4 is a perspective representation showing an upper front corner ofthe invented table in vertical position, together with a fragment of acompleted panel and one of the stabilizing means.

FIG. 5 is a perspective representation of a fragmentary portion of themeans employed for periodically moving completed courses over the tablecomprising essentially a push rod and an elongated pusher element.

FIG. 6 is a fragmentary perspective representation of the invented tableshowing the movable footing, a brick spacing means in the form ofelongated and short spacing strips, and, in phantom lines the means forperiodically moving the courses over the table as depicted in FIG. 5.

In the drawings, like characters of reference designate similar parts inthe several Figures.

INTRODUCTORY DESCRIPTION In terms consonant with the invention asclaimed, the same consists in terms of a process of placing bricksadjacently upon a table, periodically moving them across the table untilthe first placed bricks in linear array have been moved near to one edgeof the table and all bricks are intercepted against further movement;then inserting a cement grout between the bricks to bond them into panelform and permitting the grout to stiffen until it has reached panelbearing strength. After that rotating the panel into the vertical andmoving it away from the table while in the vertical, in a horizontaldirection, and in the plane of the panel or in other words parallel withthe vertically rotated table. The grout should be of such consistency,and the bricks should have such an initial rate of absorptions as willpermit rotation of the panel into the vertical in one continuous motionand its movement away, as aforesaid from the table substantiallyimmediately after the panel has been so rotated.

tated as a method of prefabricating brick panels the invention comprisesthe method steps of laying successive courses 10 of bricks upon a table12, moving them when completed over the surface of the table successiveinto panel-forming adjacency to a location 14 at which a completed panel16 may be supported after being rotated into the vertical, filling thespaces 18 between the bricks with a cementicious grout when enoughcourses have been laid to constitute a panel, next allowing the grout tostiffen while upon the table until sufficient panel-bearing strength isreached, then rotating the table with a completed panel upon it into thevertical when the grout has acquired sufficient brick-bearing strength,and then moving the panel while in the said vertical position away fromthe surface of the table for further curing and storage.

The movement of the panel while in vertical position is horizontal andin its plane. A movable footing is initially placed upon the table, withthe first course 22 of bricks against the footing as shown in FIG. 6.The footing is caused to move with the courses over the surface of thetable in advance of the leading or footing course until it reacheslocation 14 (i.e., the location at which a completed panel may besupported upon the footing after the panel has been rotated into thevertical). The footing 20 is caused to rotate with the table beingsupported at this time at location 14. Brick-spacing means 24 are placedover the table, the bricks 26 being placed between them. The saidbrick-spacing means 24 are placed between the bricks during the layingof each course and before laying each successive course 10. Thebrick-spacing method consists of laying an elongated spacing strip equalto the width of a mortar joint beside and parallel with each course uponthe completion of that course together with laying a short spacing strip30 of similar width at right angles to the elongated strip between eachbrick of each course next following the placing of each brick. Thesuccessive courses of bricks are laid upon the table adjacent the edge32 opposite the edge 34 about which table 12 rotates.

As apparatus the invention comprises means 36 for rotating the tableinto the vertical following the production of the panel 16, thebrick-spacing means 24 aforesaid, panel supporting means 38 comprisingat least first means 20 (i.e., the footing so numbered) and second means40, the second means facilitating the movement of the first means andthe panel away from the table upon rotation of the table into thevertical with a self-supporting panel thereon, and means 43 forperiodically moving successive courses 10, as completed, toward means 40until sufficient bricks to constitute a complete panel are in suchposition with respect to means 40 as to be supported thereby when thetable has been rotated into the vertical.

Footing 20 is elongated and second means 40 are secured to table 12 soas to project upwardly therefrom (when the table is horizontal as inFIG. 3 and horizontally therefrom when the table is vertical as in FIG.2) to intercept the first means or footing 20. The second means 40 alsohave means 42 for facilitating the movements of the footing 20 with thepanel upon it away from the table and in the vertical. Means 42 may alsobe defined as roller-means and from FIG. 2 it will be seen that theyfacilitate horizontal movement of the footing and panel in the plane ofthe panel when vertical. Table 12 is rotatable about edge 34, thecourses of bricks being laid adjacent edge 32. Means 42 compriseessentially a push rod 44 and an elongated brick-course contactingpusher element 46. Stabilizing means 48 are provided for use when panelhas reached the vertical and permit the panel to move horizontally inthe plane thereof. Roller means 42 comprise an elongated platform 50projecting from table 12 at right angles to the brick contacting surfacethereof and relatively adjacent edge 34 which edge of course is thelower edge when the table is rotated into the vertical, platform 50embodying an elongated frame 52 and a set of parallel rollers 54transversely spanning the frame so as to lie axially at right angles tothe table surface.

DETAILED DESCRIPTION Proceeding to a more detailed description of theinvention in general terms to complete the foregoing introductorydescription, it is explained that the table collectively designated 12consists essentially of a supporting structure 56 of the form adequatelyillustrated in the accompanying FIG. 1, the table including a suitablesurrounding frame 58 projecting posteriorly of the table supportingplate 60, and bracing generally designated 62 between and within theaforesaid frame.

The table is pivotally mounted upon the supporting structure by means ofthe bearings 64, the means for rotating the table into the vertical 36taking the form of pneumatic or the like piston and cylinder assemblies66 which need not be described in detail beyond stating that they alsoare pivotally mounted at the lower ends 68 to the pairs of support beams70 and at the upper ends suitably to the bracing 62.

Upon the two opposite side edges 72 and 74 of supporting plate 60 andpivotally mounted for rotation as clearly depicted in the accompanyingFIGS. 1 and 3 are sidewalls 76 and 78. By means of the hinge assemblies80 these sidewalls may be rotated as indicated by arrow 82 clear out ofthe way of the plane of supporting plate 60 to avoid obstructing thepassage of panel 16 when the same travels in the direction of arrow 84or as best illustrated in the accompanying FIG. 2.

The second means 40 of the panel supporting means 38 is in turnsupported upon the set of short channels 86, these channels being weldedvia the upper flange thereof to the adjacent portion of the surroundingframe 58.

The first means or footing of the panel supporting means generallydesignated 38 may be a heavy bean of any suitable material such as wood;alternatively it may be in the form of a steel channel or steel boxform, It will of course be apparent that the set of parallel rollers 5.4are joumaled via trunnions projecting into the longitudinal 88 andsuitably capped by the bolts 90. The brick-spacing means collectivelydesignated 24 may take any of a variety of forms. It may for example bein the form of a grid which could be lowered onto the table, the bricks26 being placed within the openings of the grid. The form ofbrick-spacing means shown however is believed already to have beensufficiently described, it being understood that the spacing strips 28and 30 are preferably of rubber, plastic or the like and of square crosssection as illustrated. The pusher element 46 is in the form of anelongated plate and it will be noted that the lower edge thereof israbbetted as at 92 exactly to accommodate one of the elongated spacingstrips 28. The stabilizing means 48 more specifically described consistsof a set of bearing blocks 94 through the bearings 96 of which extendthe rods 98. On the anterior ends of the rods are tubular receptacles100 to receive the right angularly disposed rods 102. Telescopicallyrelated to rods 102 are the rods 104 at the distal ends of which paddeddiscs are attached. The rods 98, and 102 may be adjusted in the bearings96 and 100 as by the tightening screws 108 for example. Rod 104 may besimilarly adjusted by means of a tightening screw (not shown) projectingthrough the pair of outwardly projecting wings 110 (between which therod 102 may be slotted). The disc 106 may rotate upon the end of thenonrotatable rod 104. Alternatively by means of obvious variations, therod 104 and the disc may be caused to rotate simultaneously.

OPERATION Brick-placing workers standing along the edge 32 of the tablereceive bricks in their left hand as from a conveyor belt or the likeand place them in courses, it being understood that the footing 20 haspreviously been laid down. upon the supporting plate 60 parallel withedge 32 and a few inches from it so that at least the first or footingcourse 22 may be laid against the footing 20. The workers place a brickand then a short spacing strip 30 until the first course is complctcd.When that has been done, an elongated spacing strip 28 is placed againstthe footing course and the next successive course (shown in full linesin the accompanying FIG. 6) is laid. When one, two, three or fourcourses have been laid, (according to how far inboard of the edge 32 thefooting 20 was initially placed) it will be necessary to move the set ofsuccessive courses and the footing 20 rightwardly with respect to theaccompanying FIGS. 3 and 6 utilizing the means 42. The pusher element orbar 46 may be manually operated or it may be automatically operated asby pneumatic means. In either event, it will cause the aforesaid coursesand the footing to move sufficiently far over supporting plate 60 topermit the laying or placing of the next one or few courses and so onuntil a panel 16 of sufficient size has been formed. By the time it isformed, as a rule, the footing 20 and the next successive courses willhave been moved over sufficiently far to make contact with the secondmeans 40, in other words, the elongated projecting frame and set ofrollers 52 and 54.

A cement grout will now be poured between the bricks and the table willpreferably be vibrated by means of the vibrators 112 (FIG. 1). To makecertain that the courses and all cores in the bricks are satisfactorilyfilled. The consistency of the grout should be such that either ofitself, or by said consistency combined with previous wetting of thebricks, an initial rate of absorption is achieved such that the groutwill acquire adequate bearing strength in, say 15 minutes although ofcourse it is not intended by this statement to indicate any limitationto such period or any period. A 15-minute dwell may however be spent insuch operations as rotating the bulkheads or sidewalls 76 and 78. Whenthe cement has acquired sufficient bearing strength however, the tableis rotated as indicated by arrow 114 into the vertical whereupon themeans 42, or elongated frame 52 will take the weight of the panel 16after which the same may be moved in its plane as indicated by arrow 84in the accompanying FIGS. I and 2 onto an adjacent elongated rollerassembly 116, the bearing surface of the rollers 118 being coplanar withthe corresponding bearing surface of the set of rollers 54. Two forms ofbrick course have been depicted, that of FIGS. 2, 3 and 4 wherein theyhave been laid upon the supporting plate 60 on edge, and FIGS. 5 and 6where the bricks are shown lying upon the supporting plate in facingcontact therewith rather than edge contact. Obviously any form ofcourse-laying may be resorted to with the means and method which havebeen described. Obviously also other monolithic forms are capable ofbeing prefabricated into panel form within the ambit of this invention,and as soon as a panel 16 has been completely discharged onto the rollerassembly l6, sidewalls or bulkheads 76 and 78 may be rotated into theposition of FIG. 1 or 3 again, locked up (by obvious means which havenot therefore been detailed) and the table lowered counterclockwise inreadiness for prefabrication of the next panel thereon.

CONCLUSION Having regard to the foregoing, generally stated the inventedmethod consists in the individual or collective steps of prefabricatinga panel upon a table by prespacing all the bricks thereof before pouringa cement grout over the panel; prepositioning a panel supporting fittingon the table in advance of the first brick course; pushing the coursesas they are completed across the table with the supporting footing untilthe footing is intercepted by a roller panel supporting assemblyprojecting from the table parallel with and adjacent the edge aboutwhich the table rotates into the vertical until the whole panel has beenpushed as far as possible; pouring the cement upon the panel to enterthe spaces between bricks; rotating the table with completed panelthereon into the vertical; and rolling the panel away from the tablewhile the table is vertical in the plane of the panel.

It should finally be mentioned however in qualification of the foregoingthat by the modification of positioning projecting upstanding dowelsupon the edge 34 (FIG. 1) of the table attachment of the elongated frame52 and roller set to the table and consequent rotation with it can beavoided. in such a modification, the frame 52 and set of rollers wouldsimply remain secured to the floor on suitable supports alongside thetable. The set of dowels would support the footing beam and brick panelwhile the table is rotating and in the final stages of rotation thesedowels (now practically horizontal and finally completely horizontal)would subside slightly below the level of the bearing plane of thestationary elongated frame which would thereupon take the load of thefooting and panel. It should also be noted that although it has beenstated that the movable footing is initially placed adjacent the makingedge of the table (i.e., in advance of the footing course) this need notnecessarily be so. Thus the movable footing could if desired beinitially placed against the second means the elongated roller equippedframe 52.

Various modifications may be constructed or performed within the scopeof the inventive concept disclosed. Therefore what has been set forth isintended to illustrate such concept and is not for the purpose oflimiting protection to any herein particularly described embodimentthereof.

What is claimed is:

1. Apparatus for facilitating the construction of prefabricated brickpanels, characterized by the combination with a table of:

i. means for rotating said table into the vertical with a cementitiouslygrouted and self-supporting brick panel thereon,

ii. means for fabricating said brick panel upon said table, iii brickpanel supporting means comprising at least:

a. first means movable with said panel and in contact with the footingcourse thereof, and,

b. second means in the vicinity of one of the edges of said table forsupporting said first means and said panel, said second meansfacilitating the movement of said first means and said panel away fromsaid table after rotation thereof into the vertical with aself-supporting panel thereon. said first means of said panel-supportingmeans being In the form of an elongated footing against which thefooting or first course of a panel in course of construction is placed,said second means projecting upwardly from said table when said table ishorizontal, and rotating with it to intercept and support said firstmeans and said panel.

2. Apparatus according to claim 1 in which said second means areadditionally characterized by including means for facilitating themovement of said first means with a completed vertical panel supportedthereon, away from said table while in the vertical. 1

3. Apparatus according to claim 2 in which said second means areadditionally characterized by including roller means for facilitatinghorizontal movement of said first means, and movement of said panel awayfrom said table.

4. Apparatus according to claim 3 in which said second means areadditionally characterized in that said roller means are so constructedand designed as to facilitate horizontal movement of said first meansand said panel in the plane of said panel and hence parallel with saidtable.

5. Apparatus according to claim 4 in which said roller means comprise anelongated platform projecting from said table at right angles to thebrick-contacting surface thereof and relatively adjacent the edge ofsaid table which is lowest when said table is rotated into the vertical,said platform embodying in combination an elongated frame and a set ofparallel rollers transversely spanning said frame so as to lie axiallyat right angles to said table surface.

6. Apparatus according to claim 4 in which said table is rotatable aboutone edge thereof, said courses of bricks being laid adjacent theopposite edge.

7. Apparatus according to claim 6 in which said means for periodicallymoving said completed courses over said table comprise essentially apushrod and an elongated brick-course contacting pusher element securedsubstantially at right angles to said rod.

8. Apparatus according to claim 7 which includes means for stabilizingsaid panel when it has reached the vertical, said stabilizing meanspermitting said panel to move horizontally in the plane thereof.

9. Apparatus according to claim 8 which is also characterized in thatsaid brick-spacing means embody:

i. elongated strips of material equal to the width of a mortar course,said elongated strips being laid on said table beside and parallel witheach course upon the completion of each course,

ii. short spacing strips of material equal to the width of each brickcourse, said short spacing strips being adapted and designed to be laidat right angles to said elongated strips between each brick of eachcourse next following the placing of each brick.

1. Apparatus for facilitating the construction of prefabricated brickpanels, characterized by the combination with a table of: i. means forrotating said table into the vertical with a cementitiously grouted andself-supporting brick panel thereon, ii. means for fabricating saidbrick panel upon said table, iii. brick panel supporting meanscomprising at least: a. first means movable with said panel and incontact with the footing course thereof, and, b. second means in thevicinity of one of the edges of said table for supporting said firstmeans and said panel, said second means facilitating the movement ofsaid first means and said panel away from said table after rotationthereof into the vertical with a self-supporting panel thereon, saidfirst means of said panel-supporting means being in the form of anelongated footing against which the footing or first course of a panelin course of construction is placed, said second means projectingupwardly from said table when said table is horizontal, and rotatingwith it to intercept and support said first means and said panel. 2.Apparatus according to claim 1 in which said second means areadditionally characterized by including means for facilitating themovement of said first means with a completed vertical panel supportedthereon, away from said table while in the vertical.
 3. Apparatusaccording to claim 2 in which said second means are additionallycharacterized by including roller means for facilitating horizontalmovement of said first means, and movement of said panel away from saidtable.
 4. Apparatus according to claim 3 in which said second means areadditionally characterized in that said roller means are so constructedand designed as to facilitate horizontal movement of said first meansand said panel in the plane of said panel and hence parallel with saidtable.
 5. Apparatus according to claim 4 in which said roller meanscomprise an elongated platform projecting from said table at rightangles to the brick-contacting surface thereof and relatively adjacentthe edge of said table which is lowest when said table is rotated intothe vertical, said platform embodying in combination an elongated frameand a set of parallel rollers transversely spanning said frame so as tolie axially at right angles to said table surface.
 6. Apparatusaccording to claim 4 in which said table is rotatable about one edgethereof, said courses of bricks being laid adjacent the opposite edge.7. Apparatus according to claim 6 in which said means for periodicallymoving said completed courses over said table comprise essentially apushrod and an elongated brick-course contacting pusher element securedsubstantially at right angles to said rod.
 8. Apparatus according toclaim 7 which includes means for stabilizing said panel when it hasreached the vertical, said stabilizing means permitting said panel tomove horizontally in the plane thereof.
 9. Apparatus according to claim8 which is also characterized in that said brick-spacing means embody:i. elongated strips of material equal to the width of a mortar course,said elongated strips being laid on said table beside and parallel witheach course upon the completion of each course, ii. short spacing stripsof material equal to the width of each brick course, said short spacingstrips being adapted and designed to be laid at right angles to saidelongated strips between each brick of each course next following theplacing of each brick.